From hydrostatic to electric solutions: an efficient and sustainable evolution of heavy duty drive systems Relatore: Andrea Torcelli Azienda: Bonfiglioli Riduttori SpA
Content Bonfiglioli Mobile & Wind Solutions Hydrostatic Drive Systems: Our Leadership Electric Drive Systems: Our Vision Bonfiglioli E-Solutions Key Compentences
Content Bonfiglioli Mobile & Wind Solutions Hydrostatic Drive Systems: Our Leadership Electric Drive Systems: Our Vision Bonfiglioli E-Solutions Key Compentences
Bonfiglioli Mobile & Wind Solutions Product Range
Bonfiglioli Mobile & Wind Solutions Applications
Content Bonfiglioli Mobile & Wind Solutions Hydrostatic Drive Systems: Our Leadership Electric Drive Systems: Our Vision Bonfiglioli E-Solutions Key Compentences
Hydrostatic Drive Systems: Our Leadership Axial Piston Motor integration Fit for function High Power Density Compact Reliable Widest range
Hydrostatic Drive Systems: Our Leadership Special Constructions: tailor made solutions
Content Bonfiglioli Mobile & Wind Solutions Hydrostatic Drive Systems: Our Leadership Electric Drive Systems: Our Vision Bonfiglioli E-Solutions Key Compentences
Electric Drive Systems: Our Vision Bonfiglioli Group: Vision & Mission Designing and manufacturing innovative and reliable solutions for power transmission and control in the industrial, mobile and renewable energy sectors. Encouraging and promoting sustainable and shared development worldwide, through dynamic, responsible, prompt and customer-oriented services.
Electric Drive Systems: Our Vision Advantages of electric drives Reduced Fuel Consumption: 35 Designed for normal (average) operating conditions: both the electric system and the diesel engine (hybrid sytems) work in the area of the highest efficiency. 30 25 20 15 98% % Time % Time Roading Spraying 10 Electrical machines can run faster and can be overloaded current for the short time when peak torque is needed 5 0 0-5% 5-9% 9-14% 14-19% 19-24% 24-28% 28-33% 33-38% 38-42% 42-47% 47-52% 52-57% 57-61% 61-66% 66-71% 71-75% 75-80% 80-85% % Max wheel torque Power can be recovered when braking or travelling downhill. Reduced Environmental Impact: reduced gas emission and noise level Additional Features: The electric drives allow for additional features such as diagnostics, independent wheel control, and electric disengagement (from 4WD to 2WD).
Electric Drive Systems: Our Vision Target Applications
Electric Drive Systems: Our Vision Critical Requirements Performances (thermal) Dimensions Efficiency (higher speed) System Degree of protection System cost Time to Market (responsiveness) Motor Technology: Modular Approach (one does not fit all) Develop Internal Engineering Competences (work with customers / evaluate multiple solutions quickly)
Electric Drive Systems: Our Vision Target Applications: Example Agricultural Equipment: Self propelled Sprayers Windrowers Forestry Traction Motor Multistage Planetary drive
Electric Drive Systems: Our Vision Target Applications: Example Main Motor Transit mixer drives Proximity sensor Mechanical disengagment Emergency Motor
Electric Drive Systems: Our Vision Target Applications: Example Light Commercial Vehicles E-4WD differential drive units Clutch disconnect
Content Bonfiglioli Mobile & Wind Solutions Hydrostatic Drive Systems: Our Leadership Electric Drive Systems: Our Vision Bonfiglioli E-Solutions Key Compentences
Bonfiglioli E-Solutions Approach Standard Motors: from BN/BE to BT performances optimized for the applications BN - BE BT High Power Density Motors: BPD Technology Development of integrated solutions
Bonfiglioli E-Solutions BPD Motors Main Benefits: High Power Density NO Permanent Magnets Compact Design Robustness High Dynamic (Low Inertia) Low Noise and Vibrations
Bonfiglioli E-Solutions BPD Motors SRM Motor: Torque produced by flux barriers High fill factor: flat wires inserted with patented tooling End Windings Traditional Hairpin Compact & Powerful Design: High slot fill factor up to 80-85% Reduction of end windings height High quality process Rotor Technology Flexibility
Content Bonfiglioli Mobile & Wind Solutions Hydrostatic Drive Systems: Our Leadership Electric Drive Systems: Our Vision Bonfiglioli E-Solutions Key Compentences
Key Competences Electric Motor 2D Finite Element Electromagnetic simulation 3D Lumped Parameters Thermal Network Co-Simulation FEM+Thermal: Efficiency Map Laboratory Validation Geartrain Analytical Prediction of mechanical losses in planetary gearbox Vibration signature anlysis Brake Systems 2D Finite Element Electromagnetic simulation Transient Finite Element Thermal Analysis
Key Competences: E-motor (1/4) E-motor Electromagnetic FEM Flux Densities Steady State Analysis Coupling with Power Electronics Average Torque Current Absorption Power Losses Efficiency Power Electronics Currents Dynamic Analysis Torque ripple Variable Load Startup Peak Current Acceleration Torque Ripple Transient Startup
Key Competences: E-motor (2/4) Thermal Lumped-Parameters Analysis Thermal Steady State Analysis: Components Working Temperatures Thermal network Cooling system sizing Sensitivity analysis Temperatures Thermal Transient Analysis: S2, S3 S n duty analysis Definition of different duty cycles in terms of Speed and Torque Schematic Transient Sensitivity
Key Competences: E-motor (3/4) Co-Simulation FEM+Thermal Start T Hyp Efficiency Map Accurate Efficiency Maps generation at different working temperature due to co-simulation between electromagnetic and thermal analysis FEM P Losses @T Hyp Thermal T Calc =T Hyp No T Calc =T Hyp Yes End Performance @ Specified Working Temperatures
Key Competences: E-motor (4/4) Laboratory Validation
Key Competences: Gear train (1/2) Analytical Prediction of mechanical losses in planetary gearbox Gear train efficiency is calculated at specific working points by analytical evaluation of load dependent and undependent power losses Gear meshing Oil Splashing Oil Squeezing Bearing, seal, Planetary carrier
Key Competences: Gear train (2/2) Vibration signature anlysis - Test data Traceability with Serial number accessible via web - Tri-directional Accelerometers - Multiple torque levels - Multiple speed levels
Key Competences: Brake systems (1/2) 2D Finite Element Electromagnetic simulation - E/M braking force and release time - Release Power
Key Competences: Brake Systems (2/2) Transient Finite Element Thermal Analysis - Simulation of temperature distribution in the brake system during a braking cycle at high speed